Pfaff 438 Service Manual

®
438
Service Manual
PFAFF INDUSTRIEMASCHINEN GMBH KAISERSLAUTERN
From the library of: Superior Sewing Machine & Supply LLC
Instructions for Adjusting the Pfaff 438
and Illustrated Guide for Tape-Recorded Instructions
The machine we had In mind in drawing up the following instructions is a machine

which has been repaired, but still needs adjusting.
I Note: Never use aneedle rise gauge on the Pfaff 438 because its needle bar
might be damaged by the C-clamp of the gauge.
Tools, Gauges and Accessories Required for Adjusting

the Pfaff 438
1 set of screwdrivers with blades from 2-10 mm wide
1 set of wrenches from 7—14 mm
1 set of alien screw wrenches in sizes from 2—6 mm
1 cylindrical pin, 32 mm long, 6 mm dia. No. 13-030 341-05
1 feed dog gauge, Order No. 91-129 995-05
1 hook bearing bracket gauge, Order No. 91-129 996-05
1 wrapper with System 438 needles, No. 80
2 strips of white paper
1 reel of adhesive tape
sewing thread
1. Preparations for Adjusting
1.1 Determining the Different Needle Positions (Fig. 1)

1.1.1 The bearing plate at the needle bar end of the machine has four holes, which, in
conjunction with a 5-mm pin, determine the different needle positions.
1.1.2 Hole 1 = Needle rise position 2 mm (abt. Vsi") above the bottom of the needle
bar stroke
1.1.3 Hole 2 = Top of needle bar stroke
1.1.4 Hole 3 = 0,25 mm (abt. .01") past the highest point of the needle bar stroke
1.1.5 Hole 4 = 1 mm (.04") past the highest point of the needle bar stroke
Fig. 1
1.2 Removing the Cast-iron Cover (Fig. 2)
1.2.1 Turn out screws S of the cast iron cover on the back of the machine arm and
remove the cover.
1.2.2 Take up the oil in the needle vibrating eccentric housing with a sponge or re
move it with a vacuum pump.
Fig. 2
1.3 Removing Various Parts before Adjusting the Needle Bar (Fig. 3)
1.3.1 Turn out screw 6 of the presser foot and remove the presser foot.
1.3.2 Turn out screw 7 of the thread guide, too, and remove the thread guide.
1.3.3 Loosen screw 8 of the slack thread control and remove the thread slack control
from the presser bar bushing by pulling It downwards.
1.3.4 Turn out the three alien screws 9 of the cover on the underside of the machine
arm and remove the cover.
1.3.5 Insert a new System 438 needle and push it up as far as It will go.
Fig. 3
2. Centering the Needle In the Needle Hole in Sewing Direction (Fig. 4)
2.1 Bring the needle bar to its lowest position.
2.2 Loosen jam nut 10.
2.3 Loosen alien screw 11 at the bottom of the needle bar frame.
2.4 Turn eccentric stud 12 on the right-hand side of the machine arm until the needle
is centered in the needle hole in sewing direction.
2.5 In this position tighten alien screw 11 as well as jam nut 10 firmly.
Fig. 4
3. Setting the Stabilizing Rod Paraiiel to the Needle Bar (Fig. 5)
3.1 Remove the face cover.
3.2 Raise the needle bar to Its highest point.
3.3 Block the machine In this position by inserting the 5-mm cylindrical pin In hole 2
of the bearing plate.
3.4 Loosen clamp screw 15 at the bottom end of the stabilizing rod.
3.5 Loosen screw 18 (accessible from the back of the machine arm) which secures
clamp crank 19 in the machine arm.
3.6 Then loosen jam nut 16.
3.7 Turn eccentric stud 17 to set stabilizing rod 13 parallel to the needle bar.
Be careful that you don't turn the eccentric stud by 180 degrees.
3.8 Hold eccentric stud 17 in this position and tighten jam nut 16 securely.
3.9 Push up stabilizing rod 13 as far as It will go, making sure that the eccentric
stud enters the recess at its top end (see arrow in Fig. 5) and tighten clamp screw
15 on clamp crank 19 securely.
3.10 Remove the cylindrical pin from the bearing plate.
3.11 Bring the needle bar to its lowest point and tighten screw 18 on the back of the
machine firmly.
Fig. 5
4. Adjusting the Stitch Width Control
4.1 Zeroing the Needle for Straight Stitching (Fig. 6)
4.1.1 Flick needle position lever 20 to its central position.
4.1.2 Loosen straight-stitch regulating screw 23 and stop screw 24 for limiting the
maximum stitch width.
4.1.3 Loosen clamp screw 26 of locking lever 22 and let lever 22 swing back until its
spring is completely relaxed.
4.1.4 In this position, tighten clamp screw 26 again.
4.1.5 Move stitch width lever 21 counter-clockwise as far as it will go, that means
towards "0".
4.1.6 Turn on the master switch and let the machine run slowly. Move stitch width
lever 21 to the left until the needle bar stops swinging sideways.
4.1.7 In this position, push straight-stitch regulating screw 23 to the right as far as it
will go and tighten it.
4.2 Adjusting the Stitch Width Scale (Fig. 6)

4.2.1 Move stitch width lever 21 to the right as far as it will go.
4.2.2 Loosen both screws 25 of the stitch width scale.
4.2.3 Adjust the scale until the zero mark on the scale is opposite the mark on the
flange of the stitch width lever.
4.2.4 In this position, tighten both screws 25 of the scale securely.
Fig. 6
4.3 Limiting the Maximum Stitch Width (Fig. 7)
4.3.1 Move stitch \wjdth lever 21 to the left until the mark on its flange is opposite the
mark indicating the maximum stitch w/idth on the scale.
4.3.2 Move stop screw/ 24 which limits the maximum stitch width to the left as far as
it will go and tighten it.
li for cerfoin sewing operations your machine should hove been equipped with a needle piole
whose hole is smoller thon the widest needle throw, limit the stitch width according to the width
ol the needle hole rother than the groduotion mark on the stitch width scale.
4.4 Adjusting the Locking Lever (Fig. 7}

4.4.1 Loosen clamp screw 26 of locking lever 22.
Make sure the pressure spring in the locking lever does not fail out.
4.4.2 Pull locking lever 22 forward until it contacts stitch width lever 21.
4.4.3 In this position, turn hinge stud 27 in or out until locking lever 22 has just the
right amount of play. Then tighten clamp screw 26 securely.
Fig. 7
5. Adjusting the Needle in the Needle Hole Sideways (Fig. 8)
5.1 Make sure that the stitch width lever is stiil In its central position and the stitch
width lever is turned to "0".
5.2 Bring the needle bar to its lowest position.
5.3 Loosen jam nut 10 of eccentric stud 28 on the underside of the machine arm.
5.4 Now turn eccentric stud 28 until the needle is centered in the needle hole side
ways.
5.5 Retain eccentric stud 28 in this position and tighten jam nut 10 firmly.
Fig. 8
6. Adjusting the Needle Throw (Fig. 9)
6.1 Loosen both screws 29 of the needle vibrating eccentric just sufficiently to per
mit the eccentric to be turned on its shaft against strong resistance.
6.2 Bring the needle bar to its highest point. Insert the 5-mm pin in hole 2 of the
bearing plate, thus blocking the machine with the needle bar in its highest posi
tion.
6.3 Move the eccentric on its shaft until there is a clearance of about 5.0 mm (or
Vii") between its right-hand side and the wall of the casting.
6.4 Turn the eccentric on its shaft until the needle bar ceases vibrating while the
stitch width lever is moved to and fro.
6.5 Pull the cylindrical pin out of the bearing plate.
6.6 Do not tighten screws 29 of the needle vibrating eccentric yet.
2®(i((0
Fig. 9
7. Adjusting the Needle Throw in Relation to the Central Needle Puncture (Fig. 10)
7.1 Move the needle position lever to its central position and the stitch width lever
to "0".
7.2 Place a piece of white paper under the needle. Turn the balance wheel in sewing
direction until the needle has pierced the paper slightly and then raise the needle
a little.
7.3 Hold the paper in its original position and turn the stitch width lever to the maxi
mum stitch width.
7.4 Rotate the balance wheel in its normal direction of rotation until the needle has
stitched into the paper again.
7.5 Remove the paper from under the needle, turn the balance wheel in sewing di
rection one complete turn and flick the stitch width lever back to "0".
7.6 Place the paper under the needle again and position it so that the needle enters
the first hole.
7.7 Turn the stitch width lever to the widest stitch and let the needle stitch into ttxe
paper again.
7.8 Since the two screws 29 of the needle vibrating eccentric are still loose, move
the eccentric slightly on its shaft in the direction in which the two outer needle
punctures must be moved in order to obtain a symmetrical stitch pattern. (Don't
rotate the eccentric while moving it endwise on its shaft.)
7.9 After you have completed the adjustment, tighten screws 29 and push the circlip
(see arrow in Fig. 10) up against the eccentric.
1<
) Fig. 10
10
8. Adjusting the Needle Position Lever
8.1 Fixing the Left Needle Position (Fig. 11)
8.1.1 Loosen both needle position limiting screws 30 and 31.
8.1.2 Turn needle position lever 20 to its central position and flick stitch width lever
21 to the maximum stitch width.
8.1.3 Turn the balance wheel in sewing direction until the descending needle is posi
tioned above the left end of the needle hole.
8.1.4 Place a piece of white paper over the needle hole and fix it to the machine with
adhesive tape.
8.1.5 Turn the balance wheel in sewing direction until the needle has stitched into the
paper lightly.
8.1.6 Turn stitch width lever 21 to "0" and push needle position lever 20 to the left
until the point of the needle is positioned right above the needle puncture in the
paper.
8.1.7 Push needle position limiting screw 30 up against its stop and tighten it firmly.
Leave limiting screw 31 loose, however.
Fig. 11
From the library of: Superior Sewing Machine & Supply LLC 11
8.2 Fixing the Right Needle Position (Fig. 11)
8.2.1 Flick needle position lever 20 to its central position and turn stitch width lever 21
to the maximum stitch width.
8.2.2 Rotate the balance wheel in sewing direction until the descending needle is posi
tioned above the right end of the needle hole.
8.2.3 Turn the balance wheel in sewing direction until the needle has again stitched
into the paper lightly.
8.2.4 Turn stitch width lever 21 to "0" and push needle position lever 20 to the right
until the point of the needle is positioned above the needle puncture made last.
8.2.5 Push needle position limiting screw 31 against its left stop and tighten it securely.
Fig. 11
12
9. Adjusting the Stitch Length Scale Ring (Fig. 12)
9.1 Loosen the scale ring screw (see arrow).
9.2 Turn the stitch length dial next to the scale ring in the direction in which the
reverse-feed control is caused to move downwards, turning it as far as it will go.
9.3 Turn the scale ring so that its "0" mark is exactly in line with the graduation
mark on the reverse-feed control.
9.4 In this position tighten the scale ring screw firmly.
Fig. 12
10. Zeroing the Feed Motion (Fig. 13)
10.1 Unscrew the gear case cover, making sure that any oil that might run out is
collected and the foam-piastic pad is removed.
10.2 Turn the stitch length dial to "0".
10.3 Loosen both ciamp screws 32 on the feed regulating crank.
10.4 Rotate the feed regulating crank on its shaft until the feed rock shaft crank
makes no perceptible movement when you turn the balance wheel.
10.5 In this position, tighten both clamp screws 32 of the feed regulating crank.
Fig. 13
14
11. Adjusting the Feed Driving Motion (Fig. 14)
11.1 Loosen both screws 33 on the feed driving eccentric just sufficiently to permit
the eccentric to be turned on its shaft against strong resistance.
11.2 Rotate the balance wheel until the needle bar is positioned about 1.0 mm (V64")
past its highest point.
11.3 To block the machine in this position, insert the cylindrical pin in hole 4 of the
bearing plate.
11.4 Set the machine for its longest stitch.
11.5 Turn the feed driving eccentric on Its shaft until its notch points forward.
11.6 Continue turning the feed driving eccentric until the feed rock shaft crank re
mains completely motionless when the reverse-feed control Is moved up and
down.
11.7 Hold It in this position, making sure that the feed driving eccentric does not
become wedged sideways and tighten one of the screws 33.
11.9 Pull the cylindrical pin out of the hole in the bearing plate and tighten the second
feed driving eccentric screw firmly.
Fig. 14
12. Adjusting the Feed Lifting Motion (Fig. 15)
12.2 Loosen both screws 34 of the feed lifting eccentric.
12.3 Turn the balance wheel until the needle bar has reached a point 0.25 mm (.01")
past the top of its stroke and retain it in this position by inserting the cylindrical
pin in hole 3 of the bearing plate.
12.4 Rotate the feed lifting eccentric on its shaft until the feed lifting shaft crank Is
at its lowest point.
12.5 Keep it in this position and tighten the accessible screw 34 of the feed lifting
eccentric, making sure that the two discs are up against the feed lifting connec
tion.
12.6 Remove the cylindrical pin from the bearing plate and tighten the second screw
of the feed lifting eccentric.
Fig. 15
16
13. Setting the Presser Foot at the Correct Height (Fig. 16)
13.1 Replace the cover on the underside of the machine arm and tighten the three
alien screws.
13.2 Push the slack thread control on the presser bar bushing so that it will not be
struck by the needle bar when it has reached its lowest point and tighten Its
set screw.
13.3 Screw on the presser foot as well.
13.4 Lower the needle into the needle hole and make sure the needle position lever
is in its central position and the stitch width lever points to "0".
13.5 Loosen clamp screw 35 which is partly concealed in the front part of the machine.
13.6 Raise the presser foot and push the feed dog gauge under it.
13.7 Raise the presser bar lifter.
13.8 Adjust the presser foot sideways so that the needle is centered In the needle
slot exactly.
13.9 Push the presser bar lifting bracket downwards as far as it will go and tighten
clamp screw 35. Then remove the gauge from under the presser foot.
(There should now be a clearance of 7.0 mm (abt. 'Az") between the presser
foot and the needle plate).
Fig. 16
14. Adjusting the Feed Dog (Fig. 17)
14.1 Turn the balance wheel until the needle bar has reached a position 0.25 mm
(.01") past its highest point and block the machine by inserting the cylindrical pin
in hole 3 of the bearing plate.
14.2 Set the stitch length dial on "0".
14.3 Loosen both clamp screws 36 on the feed lifting shaft crank.
14.4 Loosen both clamp screws 37 on the feed rock shaft crank, too.
14.5 Place the feed dog gauge so under the presser foot that both its ends are in
line with the front and rear edges of the needle plate. Lower the presser bar
lifter to let the presser foot down on the feed dog gauge.
14.6 Center the feed dog in the feed slot lengthwise.
14.7 Turn the feed lifting shaft crank until the feed dog is up against the underside
of the gauge.
14.8 Turn eccentric bushing 38 below the feed rock shaft crank until the feed dog is
set parallel to the underside of the feed dog gauge.
14.9 Tighten both clamp screws 37 of the feed rock shaft crank securely.
14.10 Also tighten both clamp screws 36 of the feed lifting shaft crank, making sure
that the feed dog still contacts the gauge.
14.11 Remove the feed dog gauge from under the presser foot and pull the cylindrical
pin out of the bearing plate.
Fig. 17
18
15. Adjusting the Hook Bearing Bracket (Fig. 18)
15.1 Loosen the clamp screw on the bobbin case opener and swing the latter to the
right.
15.2 Strip the bobbin case position finger.
15.3 Loosen the two hook set screws and pull the sewing hook off its shaft.
15.4 Unscrew the bed slide and remove it.
15.5 Remove the needle plate and the feed dog as well.
15.6 Loosen alien screw 39 on the bedplate (see circle in Fig. 18) and release the
taper key of the hook bearing bracket underneath this screw by tapping the
head of the alien screw lightly with a hammer.
15.7 Screw on the hook bearing bracket so that numbers 438 and 439 can be read
from the front. (See circle in Fig. 18.)
15.8 Turn or move the hook bearing bracket in such a way that the hook shaft con
tacts both the vertical and horizontal surfaces of the gauge.
15.9 In this position, firmly tighten alien sorew 39 of the taper key and remove the
gauge.
Fig. 18
19
16. Adjusting the Sewing Hook
16.1 Place the sewing hook without bobbin case on the hook shaft in such a way that
its point is at the top.
16.2 Hold the sewing hook steady while rotating the balance wheel until the needle
bar has passed its lowest point and has risen 2.0 mm (abt. Vs*").
16.3 Insert the cylindrical pin in hole 1 of the bearing plate so that the machine is
blocked in this position (needle rise position).
16.4 Make sure the needle position lever is still in Its central position and the stitch
width lever points to "0".
16.5 Tighten one of the hook set screws just sufficiently to allow the sewing hook to
be turned on its shaft against strong resistance.
16.6 Turn or move the sewing hook until there is a clearance of about 0.1 mm (.004")
between the hook point and the needle. Make sure that the point of the sewing
hook is positioned exactly behind the needle.
16.7 In this position, tighten both hook set screws firmly.

16.8 Remove the cylindrical pin from the hole of the bearing plate.
16.9 Screw on the bobbin case position finger so that it is positioned in the slot of
the bobbin case base and that there is a clearance of about 0.5 mm (.02") be
tween its front edge and the bobbin case base.
20
17. Setting ttie Needle Bar at the Correct Height (Fig. 19}
17.1 Flick the stitch width lever to "0" and the needle position lever to its left position.
17.2 Rotate the balance until the hook point Is positioned exactly behind the needle.
17.3 Loosen both clamp screws 40 on the needle bar connecting stud.
17.4 Push the needle bar up or down until the hook point is positioned 0.5 mm (.02")
above the top of the needle eye (see circle in Fig. 19).
17.5 In this position, tighten both clamp screws 40 securely, making sure that the
thread guide of the needle holder points forward.
V
Fig. 19
21
18. Tensioning the Driving Belt in the Gear Case (Fig. 20)
18.1 Loosen screw 41 of the eccentric bushing in the gear case.
18.2 Move the eccentric bushing endwise until the driving belt is positioned in the
middle of the sprocket driving the bobbin case opener eccentric.
18.3 Rotate the eccentric bushing without moving it endwise until the belt is suffi
ciently taut, but be careful not to tension it too much as this would cause hard
running.
18.4 In this position, tighten screw 41 of the eccentric bushing securely.
Fig. 20
22
19. Adjusting the Bobbin Case Opener (Fig. 21)
19.1 Loosen alien screw 42 of the eccentric bearing bushing of the bobbin case
opener shaft which is located in the hook bearing bracket.
19.2 Push the bobbin case opener, which is still swung out, against the clamp crank
underneath. Then push up the eccentric bushing while swinging the bobbin case
opener finger towards the right until it contacts the lug of the bobbin case base.
19.3 Turn the eccentric bushing in such a way that the top edge of opener finger is
in line with the inner side of the bobbin case base (see middle circle of Fig. 21).
19.4 In this position, push the eccentric bushing endwise until there is a clearance
of 0.8 mm (.03") between the bottom edge of the opener finger and the rim of
the bobbin case (see lower circle of Fig. 21).
19.5 In this position, tighten alien screw 42 of the eccentric bushing firmly.
19.6 Turn the balance wheel until the bobbin case opener finger is at the extreme
left of its stroke.
19.7 Now turn the opener finger together with the bobbin case base towards the right
until there is a clearance of abt. 0.3 mm (.01") between the bobbin case position
finger and the right wall of the position slot in the bobbin case base (see upper
circle of Fig. 21).
19.8 In this position, tighten ciamp screw 43 of the bobbin case opener firmly, making
sure that the bobbin case opener is up against the clamp crank underneath.
A
Fig. 21
23
20. Adjusting the Bobbin Case Opener Eccentric (Fig. 22)
20.1 Loosen the three screws 45 of the bobbin case opener eccentric.
20.2 Turn the screw in the middle in just sufficiently to allow the eccentric to be
turned on its shaft against strong resistance.
20.3 Turn the balance wheel until the needle bar has passed its lowest point and
risen 2 mm (abt. V64").
20.4 Insert the cylindrical pin in hole 1 of the bearing plate to block the machine in
this position.
20.5 Now turn the eccentric on its shaft until the bobbin case opener finger Is at the
extreme right of its stroke.
20.6 Remove the cylindrical pin from the bearing plate.
20.7 Tighten the three screws 45 of the bobbin case opener eccentric, beginning with
the screw in the middle
Fig. 22
24
21. Adjusting the Oil Chedt Valve (Fig. 23)
21.1 Loosen oil check valve screw 46.
21.2 Push the actuating plunger of the centrifugal governor to the left as far as it
will go.
21.3 Adjust the position of the oil check valve until there is a clearance of 1.0 mm
(.04") between the valve rod and the actuating plunger.
21.4 In this position, tighten oil check valve screw 46 securely.
21.5 Replace the foam-plastic pad in the gear case and position it so that the cast
iron fin enters the smallest cutout in the pad.
21.6 Clean the gear case gasket and screw on the gear case cover. Tighten the
screws evenly crosswise.
Fig. 23
22. Inserting the Oil Tube in the Oil Retainer Ring (Fig. 24)
22.1 Loosen alien screw 47 on the bedplate.
22.2 Insert the small bent copper tube in the hole of the oil retainer ring (see arrow
in Fig. 24).
22.3 Tighten alien screw 47 securely.
Fig. 24
26
23. Adjusting the Slack Thread Control (Fig. 25)
23.1 Flick the needle position lever to its central position and turn the stitch width
lever to "0".
23.2 Bring the needle bar to its lowest point.
23.3 Loosen screw 8 of the slack thread control.
23.4 Adjust the position of the slack thread control on the presser bar bushing so that
the lower edge of the slack thread control wire is in line with the top edge of the
hole in the thread guide (see circle in Fig. 25).
23.5 In this position, tighten screw 8 of the slack thread control, making sure that the
needle bar is opposite the center of the slack thread control wire.
Special sewing operolions may make it neccessary however, to set the slock thread control higher
or lower.
Fig. 25
27
24. Adjusting the Tension Release (Fig. 26)
(This odiuslmenF does nof apply to machines equipped with subcl. -900 threod trimmer)
24.1 Take out the four screws in the arm rear cover and swing the rear cover away
towards the right.
24.2 Replace the needle plate without screwing It down, however.
24.3 Lower the presser bar lifter.
24.4 Loosen clamp screw 48 on the connecting rod crank which is accessible through
the left aperture in the machine arm. If the connecting rod is not pulled down by
spring action, push it down as far as It will go.
24.5 Operate the presser bar lifter to raise the presser foot.
24.6 Place the feed dog gauge under the presser foot with Its recess up.
24.7 Lower the presser bar lifter to let the presser foot down into the recess of the
gauge.
24.8 Loosen screw 49 on the tension release cam.
24.9 Move the cam on its shaft until it Is exactly opposite the tension release plunger.
24.10 Turn the presser bar lifter upwards until a noticeable resistance Is felt.
24.11 Turn the tension release cam until it contacts the tension release plunger and
tighten screw 49 securely.
24.12 Remove the feed dog gauge from under the presser foot.
24.13 Swing the presser bar lifter down to lower the presser foot onto the needle plate.
24.14 Tighten clamp screw 48 securely, making sure that the circllp on the tension
release shaft contacts the face side of the machine casting, and that the connect
ing rod crank is likewise up against the casting. (With the presser bar lifter rais
ed to Its highest point, the tension should now be released so that there is a
clearance of about 0.5 mm (.02") between both tension discs.)
48
:? Fig. 26
28
25. Adjusting the Knee Lever (Fig. 27)
25.1 Limiting the Knee Lever Motion
25.1.1 Place the feed dog gauge under the presser foot with its recess down.
25.1.2 Operate the presser bar iifter to lower the presser foot onto the gauge.
25.1.3 Push the knee lever into its socket.
25.1.4 Loosen the jam nut on stop screw 51 which limits the knee lever motion.
25.1.5 Turn stop screw 51 out a few turns.
25.1.6 Push the knee lever sideways until a noticeable resistance is felt and hold it in
this position. (Make sure the presser foot is not raised from the gauge in the
process).
25.1.7 In this position, turn stop screw 51 in aii the way and let the knee lever return
to its normal position.
25.1.8 Turn the stop screw out one turn and tighten the jam nut.
25.1.9 Operate the knee lever now until it contacts the stop screw and remove the
gauge from under the presser foot.
(The clearance between the presser foot and the needle plate has thus been
limited to 8,0 mm (abt. Vu").
25.2 Adjusting the Knee Lever Play

25.2.1 Remove the needle plate.
25.2.2 Loosen both Jam nuts 50 on the connecting link of the knee lever socket.
25.2.3 Turn the rear nut in until there is a noticeable play between the nut and the
connecting link when you push the knee lever lightly.
25.2.4 Hold the rear nut steady with a wrench and tighten the front jam nut.
25.2.5 Pull the knee lever out of its socket again.
Fig. 27
29
26. Adjusting the Thread Check Spring and the Slack Thread Regulator (Fig. 28)
26.1 Loosen both screws 52 just sufficiently to enable the tension barrel with the
thread check spring to be turned in the tension bracket.
26.2 Rotate the tension barrel until the stroke of the thread check spring measures
about 7.0 mm (V32").
Special sewing opefotions moy moke it necessory to choose a longer or shorter stroke.
26.3 The tension of the thread check spring is regulated in the usual manner by turn
ing the tension stud.
26.4 Loosen both screws 53 and push the slack thread regulator up as far as it will go.
26.5 In this position, tighten both screws 53 securely.

The setting of the slack threod regulator is diiefly dependent on the type of thread and material
being used and has to be odjusted occordingly.
Fig. 28
From
K
the library of: Superior Sewing Machine & Supply LLC
30
Adjusting the Bobbin Winder Pulley (Fig. 29)
Engage the bobbin winder by pushing against its spindle.
Loosen both screws 54 (which can be reached through the aperture on the back
of the machine arm).
Move the pulley on the arm shaft so that it will drive the bobbin winder spindle
reliably when the bobbin winder is engaged. Make sure, however, that the pulley
does not contact the friction wheel when the bobbin winder is disengaged.
Tighten both screws 54 in the pulley securely.
Swing the cover on the back of the machine arm back to its normal position and
secure it in place with its four screws.
Loosen screw 55 of the regulating stud in the bobbin winder latch (see circle of
Fig. 29).
Move the regulating stud to the right for less thread or to the left for more thread.
Then tighten screw 55 firmly.
28. Filling the Oil Reservoirs
28.1 Fill about 100 com (or 6 cu In) of Pfaff sewing machine oil No. 280-1-120110 Into
the needle vibrating eccentric housing from the back of the machine.
28.2 Clean the contact surfaces of the cast-iron cover and screw It on with Its two
screws.
28.3 FIN Pfaff sewing machine oil No. 280-1-120110 Into the hook oil reservoir through
a hole In the oil sight glass on the front of the machine arm until It reaches the
top mark.
When replenishing the oil loter, oil flows through on overflow duct from the hook oil reservoir
into the needle vibrating eccentric housing. Top up the oil until the oil level has reached the
top mark on the oil sight glass of the hook oil reservoir.
32
29. Regulating the Hook Lubrication (Fig. 30)
29.1 Turn oil regulating screw 56 in completely, then turn it out half a turn again.
29.2 Turn on the master switch and let the machine run for about one minute.
29.3 Remove the needle plate, place a piece of white paper over the needle plate
cutout and hold it there.
29.4 Let the machine run for about ten seconds. Check to see if there Is a thin line
of spray oil opposite the hook raceway.
29.5 To regulate the flow of oil to the sewing hook, turn screw 56 in or out, as may
be required.
29.6 Replace the feed dog and the needle plate as well as the face cover, the thread
guide and the bed slide.
Fig. 30
33
Important Lubricating Pointers
When the Pfaff 438 is made ready for shipment, the oil is drained from the needle vi
brating eccentric housing. It is absolutely necessary that you fill 100 ccm (6 cu In) of
Pfaff sewing machine oil No. 280-1-120110 into this housing before the machine is put
into operation for the first time. (A sticker on the machine arm serves as a reminder).
Replenishing the oil in the hook oil reservoir can be done by the operator herself. All
she has to do Is stick the spout of the oil can into the hole in the hook oil reservoir and
top up the oil until the oil level has reached the top mark on the oil sight glass.
The gear case underneath the bedplate contains about 130 ccm (8 cu in) of Pfaff sewing
machine oil No. 280-1-120108 which has to be changed only when the gear case has
been opened for performing certain adjustments. In this case, it is recommended to re
place the two foam-plastic pads No. 91-168 393-05 and No. 91-168 394-05 also.
Important note: Use only oil No. 280-1-120108 In the gear case.
When the machine is overhauled thoroughly, put 2 ccm (abt. Va cu in) of Molykote 350
pinion grease in the hook bevel gear case. This grease may be obtained from us by
Order No. 280-1-120199.
34
Contents
1. Preparations for Adjusting 1

1.1 Determining the Different Needle Positions 1
1.2 Removing the Cast-Iron Cover 2
1.3 Removing Various Parts before Adjusting the Needle Bar 3
2. Centering the Needle in the Needle Hole in Sewing Direction .... 4
3. Setting the Stabilizing Rod Parallel to the Needle Bar 5
4. Adjusting the Stitch Width Control 6
4.1 Zeroing the Needle for Straight Stitching 6
4.2 Adjusting the Stitch Width Scale 6
4.3 Limiting the Maximum Stitch Width 7
4.4 Adjusting the Locking Lever 7
5. Adjusting the Needle in the Needle Hole Sideways 8
6. Adjusting the Needle Throw 9
7. Adjusting the Needle Throw in Relation to the Central Needle Puncture . 10
8. Adjusting the Needle Position Lever 11
8.1 Fixing the Left Needle Position 11
8.2 Fixing the Right Needle Position 12
9. Adjusting the Stitch Length Scale Ring 13
10. Zeroing the Feed Motion 14
11. Adjusting the Feed Driving Motion 15
12. Adjusting the Feed Lifting Motion 16
13. Setting the Presser Foot at the Correct Height 17
14. Adjusting the Feed Dog 18
15. Adjusting the Hook Bearing Bracket 19
16. Adjusting the Sewing Hook 20
17. Setting the Needle Bar at the Correct Height . 21
18. Tensioning the Driving Belt in the Gear Case 22
19. Adjusting the Bobbin Case Opener ; . 23
20. Adjusting the Bobbin Case Opener Eccentric 24
21. Adjusting the Oil Check Valve 25
22. Inserting the Oil Tube in the Oil Retainer Ring 26
23. Adjusting the Slack Thread Control 27
24. Adjusting the Tension Release 28
25. Adjusting the Knee Lever 29
25.1 Limiting the Knee Lever Motion 29
25.2 Adjusting the Knee Lever Play 29
26. Adjusting the Thread Check Spring and the Slack Thread Regulator . . 30
27. Adjusting the Bobbin Winder Pulley 31
28. Filling the Oil Reservoirs 32
29. Regulating the Hook Lubrication 33
Important Lubricating Pointers 34
CPMFF f
Nr. 296-12-12 853 eng!. P 269 Printed in Germany

Pfaff 438 Service Manual

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What tools and gauges are required to adjust the Pfaff 438?

What tools and gauges are required to adjust the Pfaff 438?

What are the steps to determine the different needle positions?

What are the steps to determine the different needle positions?

®

PFAFF INDUSTRIEMASCHINEN GMBH KAISERSLAUTERN

The machine we had In mind in drawing up the following instructions is a machine

Tools, Gauges and Accessories Required for Adjusting

1 set of screwdrivers with blades from 2-10 mm wide

1 set of wrenches from 7—14 mm

1 set of alien screw wrenches in sizes from 2—6 mm

1 cylindrical pin, 32 mm long, 6 mm dia. No. 13-030 341-05

1 feed dog gauge, Order No. 91-129 995-05

1 hook bearing bracket gauge, Order No. 91-129 996-05

1 wrapper with System 438 needles, No. 80

2 strips of white paper

1 reel of adhesive tape

1.1 Determining the Different Needle Positions (Fig. 1)

1.1.3 Hole 2 = Top of needle bar stroke

2.1 Bring the needle bar to its lowest position.

2.2 Loosen jam nut 10.

4.2 Adjusting the Stitch Width Scale (Fig. 6)

4.4 Adjusting the Locking Lever (Fig. 7}

5.2 Bring the needle bar to its lowest position.

9.4 In this position tighten the scale ring screw firmly.

10.2 Turn the stitch length dial to "0".

10.3 Loosen both ciamp screws 32 on the feed regulating crank.

16.7 In this position, tighten both hook set screws firmly.

18.1 Loosen screw 41 of the eccentric bushing in the gear case.

18.4 In this position, tighten screw 41 of the eccentric bushing securely.

22.1 Loosen alien screw 47 on the bedplate.

22.3 Tighten alien screw 47 securely.

23.2 Bring the needle bar to its lowest point.

23.3 Loosen screw 8 of the slack thread control.

25.2 Adjusting the Knee Lever Play

26.5 In this position, tighten both screws 53 securely.

1. Preparations for Adjusting 1

Nr. 296-12-12 853 eng!. P 269 Printed in Germany

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